Wall grommet for power connection

ABSTRACT

Provided is a wall grommet, which can be installed through the surfaces of walls to route wiring in the walls&#39; interior spaces. In particular, the wall grommet is configured for running power cords inside walls and presenting the electrical connectors of a power cord in a manner such that power cords are hidden from view. The grommet may comprise a housing, which defines an interior space that is adapted to hold either the female connector or male connector of a power cord. The housing may be configured to enclose and secure the electrical connector of the power cord in the housing.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation of U.S. patent application Ser. No.16/146,005 filed Sep. 28, 2018, which is a continuation of U.S. patentapplication Ser. No. 14/180,930 filed Feb. 14, 2014, which is acontinuation of U.S. patent application Ser. No. 13/247,573 filed Sep.28, 2011, now U.S. Pat. No. 8,651,460, which claims the benefit of U.S.Provisional Patent Application No. 61/492,179, filed Jun. 1, 2011, thecontents of which are incorporated herein by reference.

BACKGROUND

This invention has particular applicability for the installation ofaudio and video equipment, where it may be desirable to route powercords and audio/video cables inside walls.

SUMMARY

In accordance with one aspect of the invention, provided is a wallgrommet, which can be installed through the surfaces of walls to routewiring in the walls' interior spaces. In one embodiment, the grommet maycomprise a housing, which defines an interior space that is adapted tohold either the female connector (also referred to a “female end”) ormale connector (also referred to as a “male end”) of a power cord. Thehousing may have tubular construction. A wire-egress opening may beprovided in the tubular wall of the housing so that cables (e.g.,low-voltage audio/video cables) may be passed through the wire-egressopening from the wall's interior space. Also, the housing may comprisean annular flange that extends outwardly from the front opening of thehousing. The grommet's housing is adapted to be inserted through a holein the surface of a wall and the exterior flange is adapted to bemounted substantially flush with the surface of the wall. Thus, the wallgrommet can be mounted flush on the surface of a wall and the electricalconnector of the power cord may be recessed from the wall.

In another embodiment, the grommet may further comprise a wire-egresscover and/or a trim ring. The wire egress cover is configured to fit inthe interior space of the housing and cover the wire egress opening. Thetrim ring has a planar surface that defines an opening, and is adaptedto engage the housing and cover the flange.

In accordance with another aspect of the invention, provided is a wallgrommet assembly comprising two wall grommets and a power cord. The twogrommets and the power cord may be provided in accordance with thepreceding descriptions. The wall grommet assembly may be installed bycutting out two holes on the surface of a wall and running the powercord inside the wall such that the female connector comes out of thewall through one hole and the male connector comes out of the wallthrough the other hole. Then, the female connector of the power cord canbe secured in one grommet and the male connector of the power cord canbe secured in the other grommet. The grommets can each be insertedthrough holes in a wall and secured to the surface of the wall.

In accordance with yet another aspect of the invention, provided is akit for routing wiring in the interior spaces of walls. In oneembodiment the kit comprises a saw, a fish stick, two grommets and apower cord. The two grommets and the power cord may be provided inaccordance with the preceding descriptions. The saw may be anyconventional saw that can be used to cut out holes in the surface ofwalls (e.g., drywall saw). The fish stick comprises a rod with a hook(or other means for holding a cable) on one end.

BRIEF DESCRIPTION OF DRAWINGS

The foregoing summary, as well as the following detailed description ofthe preferred embodiments, is better understood when read in conjunctionwith the appended drawings. For the purpose of illustrating theinvention, there is shown in the drawings embodiments that are presentlypreferred, it being understood, however, that the invention is notlimited to the specific embodiments disclosed. In the drawings:

FIG. 1 shows a front perspective view of an exemplary power module of awall grommet;

FIG. 2 shows a back perspective view of the power module of FIG. 1;

FIG. 3 shows a cross sectional view of the power module of FIGS. 1 and 2taken along cross-sectional line C-C shown in FIGS. 1 and 2;

FIG. 4 shows a front perspective view of a wall grommet assembled with afemale connector;

FIG. 5 shows an exploded view of the wall grommet of FIG. 4 with afemale connector;

FIG. 6 shows a front perspective view of a wall grommet assembled with amale connector;

FIG. 7 shows an exploded view of the wall grommet of FIG. 6 with a maleconnector;

FIG. 8 shows a wall grommet assembly; and

FIG. 9 shows a wall grommet kit.

DETAILED DESCRIPTION

Before the present invention is described in further detail, it is to beunderstood that the invention is not limited to the particularembodiments described. It is also to be understood that the terminologyused herein is for the purpose of describing particular embodimentsonly, and is not intended to limit the scope of the claims of thepresent application.

In accordance with one aspect of the invention, provided is a wallgrommet 10, which can be installed through the surface of a wall toroute wiring in the wall's interior space. Grommet 10 can be used toroute power cords and low-voltage cables for audio and videoapplications.

In one embodiment, grommet 10 comprises a power module 100, a back cover200, a wire egress cover 300 and a trim ring 400. However, it is alsocontemplated that grommet 10, in another embodiment, may comprise only apower module 100 and a back cover 200. Still in other embodiments,grommet 10 may further optionally comprise a wire egress cover 300 or atrim ring 400.

As shown in FIGS. 1 and 2, power module 100 comprises a housing 110,which defines an interior space 120 that is adapted to hold either thefemale connector 510 (also referred to a “female end”) or male connector520 (also referred to as a “male end”) of a power cord 500. Housing 110may comprise a tubular wall 130 having a substantially tubular shapethat defines a front opening 140 and a back opening 142. Tubular wall130 extends between the front opening 140 and back opening 142 ofhousing 110. Also, a wire-egress opening 144 may be provided in tubularwall 130 of housing 110 so that the interior space 120 of housing 110communicates with a space outside of housing 110, other than through thefront and back openings 140, 142. Further, a relief cut 148 may beprovided adjacent to back opening 142 for accommodating a power cord500. As shown in the embodiment illustrated in FIGS. 1 and 2, housing110 may have an irregular tubular shape. For example, the shape of across-section transverse to a longitudinal axis Z may be asymmetricabout a horizontal axis X and/or a vertical axis Y. Further, thecross-sections transverse to the longitudinal axis Z may be non-uniform,i.e., the shape of the cross-sections transverse to the longitudinalaxis Z may vary along the longitudinal axis Z.

Additionally, as shown in FIG. 3, housing 110 may comprise an interiorwall 150. Interior wall 150 is disposed inside housing 110 and extendsfrom tubular wall 130 across interior space 120 of housing 110 to createa separation in the interior space 120 of housing 110. Interior wall 150defines a front interior space 122 and a back interior space 124 insidehousing 110. A first portion 152 of interior wall 150 preferably extendssubstantially vertically from the interior of tubular wall 130 and intointerior space 120 of housing 110. The first portion 152 of interiorwall 150 includes an electrical-connector opening 146 that connects thefront interior space 122 and the back interior space 124 of housing 110.The back interior space 124 of housing 110 is adapted to receive theelectrical connector 510, 520 of a power cord 500, such that theelectrical connector 510, 520 abuts interior wall 150 and the femalereceptacle or male prongs of electrical connector 510, 520 areaccessible through the electrical-connector opening 146.

As shown in FIGS. 5 and 7, the electrical connector 510, 520 may have abody comprising a flange 512, 522 configured to engage the interior wall150 of the housing 110 around the electrical-connector opening 146.Further, the body of the electrical connector 510, 520 may furthercomprise a front face 514, 524 that is configured to be disposedsubstantially vertically when the electrical connector 510, 520 isdisposed inside the housing 110 and the grommet 10 is mounted on asurface of a vertical wall. The body of the electrical connector 510,520 extends back from the front face 514, 524 generally perpendicularlyto the plane of the front face 514, 524. As shown in FIGS. 5 and 7, thepower chord 500 of the electrical connector 510, 520 may extendtransversely to the body of the electrical connector 510, 520 so thatthe power chord 500 can be routed vertically inside the wall. The frontface 514, 524 of the electrical connector 510, 520, which has the femalereceptacle or male prongs disposed thereon, may be configured toprotrude from the flange 512, 522 such that the front face of theelectrical connector 510, 520 extends through the electrical-connectoropening 146 when the flange 512, 522 engages the interior wall 150 ofthe housing 110 around the electrical-connector opening 146.

The front opening 140 and the front interior space 122 are adapted toprovide access to the electrical connector 510, 520 of power cord 500,which is disposed in the back interior space 124 of housing 110, so thatthe mating connector end of another power cord can be connected to theelectrical connector 510, 520 disposed in the back interior space 124 ofhousing 110. Thus, grommet 10 can be mounted flush on a surface and theelectrical connector 510, 520 of power cord 500 may be recessed from thesurface. As shown in FIGS. 5-8, grommet 10 is configured such that whengrommet 10 is mounted flush on the surface of a vertical wall, the frontface 514, 524 of the electrical connector 510, 520 is disposedsubstantially vertically and parallel to the surface of the verticalwall, and the power cord 500 extends substantially transversely to thelongitudinal axis Z of housing 110 and substantially vertically insidethe wall.

Further, as shown in FIG. 3, a second portion 154 of interior wall 150extends from the interior of the tubular wall 130 at the back edge ofthe wire-egress opening 144 and slopes/curves up and forward towardfront interior space 122 and front opening 140. This particularconfiguration of the second portion 154 of interior wall 150 guides anywires or cables that are inserted through wire-egress opening 144 towardfront interior space 122 and front opening 140. Thus, when grommet 10 isinstalled in a wall, wires or cables (e.g., low voltage audio/videocables) can be easily fed from the interior space of a wall out troughthe wire-egress opening 144 of power module 100. Further, screw posts156 may disposed on the backside of the second portion 154 of interiorwall 150, in the back interior space 124 of housing 110, for engagingfasteners 158, which secure back cover 200 to power module 100.

Also, as shown in FIGS. 1 and 2, power module 100 may comprise anannular flange 160 that extends outwardly from the front opening 140 ofhousing 110 and defines a substantially planar surface transverse to thelongitudinal axis Z of housing 110. Annular flange 160 comprises a frontsurface 162 and a back surface 164. When the housing 110 of power module100 is inserted through an appropriately sized hole in the surface of awall, the back surface 164 of flange 160 abuts the surface of the walland prevents power module 100 from falling through the hole. Extendingfrom the front surface 162 through to the back surface 164 of flange 160are at least two holes 166 adapted to receive and engage fasteners 170(e.g. screws, nails, etc.) for securing power module 100 to a wallsurface. Thus, once power module 100 is inserted through a hole in thesurface of a wall, fasteners 170 can be inserted through holes 166 offlange 160 to secure power module 100 to the wall.

Additionally, as shown in FIGS. 1 and 2, in one embodiment, toggles 172may be provided in conjunction with fasteners 170 to secure module 100on the surface of a wall. Toggles 172 comprise bores 174 that areadapted to engage fasteners 170. Toggles 172 may be disposed adjacent tothe holes 166 on the back surface 164 of flange 160, such that the bores174 of toggles 172 are aligned with the holes 166 on the back surface164 of flange 160. As shown in the embodiment of FIGS. 1 and 2, toggles172 may be held in mounts 132 provided on an outer surface of housing110. Toggles 172 and mounts 132 are preferably configured to allowtoggles 172 to pivot about a longitudinal axis of bores 174 parallel tolongitudinal axis Z. The configuration of toggles 172 and mounts 132allow toggles 172 to rotate between a dosed position (as shown in FIGS.4 and 6) to an open position (as shown in FIGS. 1 and 2) when a fastener170 is rotated in a tightening direction (e.g., clockwise). Likewise,when a fastener 170 is rotated in a loosening direction (e.g., counterclockwise), toggles 172 may rotate from an open position to a closedposition. Preferably, mounts 132 include detents 134 that preventtoggles 172 from moving in an opening direction past a certain point,such that toggles 172 are substantially radially aligned withlongitudinal axis Z of power module 100. As power module 100 is insertedthrough a hole in the surface of a wall, toggles 172 may be held in aclosed position. Once power module 100 has been inserted through a holein the surface of a wall and fasteners 170 are tightened, toggles 172may move into an open position and engage the backside of the wall tosecure power module 100 to the wall.

As shown in FIGS. 5 and 7, grommet 10 further comprises back cover 200that is adapted to engage housing 110 of power module 100 at the backopening 142. Back cover 200 comprises at least two holes 202 forreceiving fasteners 158. The holes 202 are configured to align with thescrew posts 156 so that fasteners 158 may be inserted through holes 202in back cover 200 and engage screw posts 156. Once the electricalconnector 510, 520 of power cord 500 is inserted into back interiorspace 124 of housing 110, electrical connector 510, 520 can be securedin housing 110 by attaching back cover 200 to power module 100 andinserting fasteners 158 through holes 202 and into screw posts 156.Thus, by enclosing the back interior space 124 of housing 110 with backcover 200, an electrical connector 510, 520 can held and secured in theback interior space 124 such that the female receptacle or male prongsof electrical connector 510, 520 can be accessed from the front opening140 and front interior space through the electrical-connector opening146.

Also, as shown in FIGS. 5 and 7, Grommet 10 may further optionallycomprise a wire egress cover 300. Wire egress cover 300 preferablyincludes a planar surface 310 that is shaped to match the shape of aportion of a cross section of the interior space 120 of power module 100such that the interior space—between the second portion 154 of interiorwall 150 and the interior of tubular wall 130—that leads to wire-egressopening 144 can be covered while still allowing wires or cables to bepassed through. Wire egress cover may further include arms 320 thatextend orthogonally from surface 310. Arms 320 are adapted to fit in thefront interior space 122 of housing 110 and engage the interior surfaceof tubular wall 130 so that wire egress cover 300 may be secured topower module 100. Wire egress cover 300 may also include tabs 330disposed on the free ends of arms 320. Tabs 330 are configured to engagerecesses 136 in the interior surface of tubular wall 130. Wire egresscover 300 may further include a notch 340 cut out to allow wires orcables to be passed through the wire-egress opening 144 when the egresscover 300 is installed.

Additionally, as shown in FIGS. 5 and 7, grommet 10 may furtheroptionally comprise a trim ring 400. Trim ring 400 includes asubstantially planar surface 410 that defines a central opening 420 forallowing access to the interior space 120 of power module 100. Extendingorthogonally from surface 410 is a semi-cylindrical wall 430.Semi-cylindrical wall 430 partially encircles central opening 420 onsurface 410 and is adapted to extend inwardly into interior space 120 ofhousing 110. Semi-cylindrical wall 430 is adapted to engage the interiorsurface of tubular wall 130 so that trim ring 400 may be secured topower module 100. Trim ring 400 is preferably adapted to securely fit onthe flange 160 of power module 100 without the need for fasteners. Trimring 400 is configured to cover fasteners 170 on flange 160 and providean even finished surface around the front opening 140 of power module100. Thus, trim ring 400 provides a clean finished appearance to theportion of grommet 10 that is visible after installation in a wall.

In accordance with another aspect of the invention, as shown in FIG. 8,provided is a wall grommet assembly 600. Wall grommet assembly 600 maycomprise two wall grommets 10′, 10″ (as described above) and a powercord 500. Power cord 500 preferably has a female connector 510 on oneend and a male connector 520 on the other end. Further, power cord 500preferably comprises type NM-B cable, or other type of cable that israted for use inside walls. As shown in FIGS. 4 and 5, grommet 10′ isused in conjunction with the female connector 510 of power cord 500, asshown in FIGS. 4 and 5. As shown in FIGS. 6 and 7, grommet 10″ is usedin conjunction with the male connector 520 of power cord 500, as shownin FIGS. 6 and 7. As shown in FIG. 8, wall grommet assembly 600 may beinstalled by cutting out two holes on the surface of a wall and runningpower cord 500 inside the wall such that female connector 510 comes outof the wall through one hole and male connector 520 comes out of thewall through the other hole. Then, female connector 510 can be securedin grommet 10′ and male connector 520 can be secured in the othergrommet 10″. Grommets 10′, 10″ can then be inserted through theirrespective holes in the wall and secured to the surface of the wallusing fasteners (e.g. screws, nails, etc.) through holes 166 in flange160. Additionally, other cables (e.g., low-voltage audio/video cables)may be passed through the wire-egress opening 144 of one grommet 10′,through the interior space of the wall, and out through the wire-egressopening 144 of the other grommet 10″. Wire egress covers 300 and trimrings 400 may also be secured on the power modules 100′, 100″, asdesired.

In accordance with yet another aspect of the invention, as shown in FIG.9, provided is a kit 700 for routing wiring in the interior spaces ofwalls. In one embodiment the kit 700 comprises a saw 710, a fish stick720, two grommets 10′, 10″, and a power cord 500. Saw 710 may be anyconventional saw that can be used to cutout holes in the surface ofwalls (e.g., drywall saw). Fish stick 720 comprises a rod 722 with ahook 724 (or other means for holding a cable) on one end. The rod 722may have a one-piece construction, or it may be provided in multiplesections (as shown) that are connected by connectors 726. The twogrommets 10′, 10″ and power cord 500 may be provided in accordance withthe preceding descriptions.

Saw 710 may be used to cut out holes on the surface of a wall. Once twoholes are cut out, fish stick 720 may be inserted through one of theholes and into the wall such that the hook 724 on the end of the rod 710can be accessed through the other hole. One end of the power cord 500can be secured on the hook 724 and inserted through the hole such thatthe power cord 500 can be fished through the inside of the wall bypulling out the other end of fish stick 720 through the other hole.Power cord 500 may be fished through the inside of the wall such thatone end of the cord comes out of the wall through one hole and the otherend of the cord comes out of the wall through the other hole. Then,female connector 510 can be secured in grommet 10′ and male connector520 can be secured in the other grommet 10″. Grommets 10′, 10″ can thenbe inserted through their respective holes in the wall and secured tothe surface of the wall using fasteners (e.g. screws, nails, etc.)through holes 166 in flange 160. Additionally, other cables (e.g.,low-voltage audio/video cables) may be passed through the wire-egressopening 144 of one grommet 10′, through the interior space of the wall,and out through the wire-egress opening 144 of the other grommet 10″.Wire egress covers 300 and/or trim rings 400 may also be secured on thepower modules 100′, 100″, as desired.

While the invention has been described with reference to the preferredembodiments thereof, it will be appreciated by those of ordinary skillin the art that modifications can be made to the structure and elementsof the invention without departing from the spirit and scope of theinvention as a whole.

What is claimed is:
 1. A power cord rated for use inside walls,comprising: a type NM-B cable terminating with a female receptacleconnector on one end and terminating with a male prong connector onanother end; wherein the female receptacle connector and male prongconnector are integrally formed with the type NM-B cable to form aunitary power cord; wherein each of the female receptacle connector andmale prong connector comprises a body defining a front face providingelectrical connection points, the body defining a longitudinal axisnormal to the front face; wherein the type NM-B cable extends from thebody of the female receptacle connector transversely to the longitudinalaxis of the female receptacle connector; and wherein the type NM-B cableextends from the body of the male prong connector transversely to thelongitudinal axis of the male prong connector.
 2. The power cord ofclaim 1, wherein each of the female receptacle connector and male prongconnector further comprises a flange extending from the body along aplane parallel to the front face or perpendicular to the longitudinalaxis of the body.
 3. The power cord of claim 2, wherein the flange ofeach of the female receptacle connector and male prong connector isoffset from the front face along the longitudinal axis of the body. 4.The power cord of claim 2, wherein the flange of each of the femalereceptacle connector and male prong connector extends circumferentiallyaround the body.
 5. The power cord of claim 1, wherein the type NM-Bcable extends from the body of the female receptacle connector at a 90°angle to the longitudinal axis of the female receptacle connector; andwherein the type NM-B cable extends from the body of the male prongconnector at a 90° angle to the longitudinal axis of the male prongconnector.
 6. A power cord rated for use inside walls, comprising: afirst electrical connector disposed at a first end of a cable that israted for use inside walls and a second electrical connector disposed ata second end of the cable; wherein each of the first electricalconnector and second electrical connector comprises a body defining afront face providing electrical connection points, the body defining alongitudinal axis normal to the front face; wherein the cable extendsfrom the body of the first electrical connector transversely to thelongitudinal axis of the first electrical connector; and wherein thecable extends from the body of the second electrical connectortransversely to the longitudinal axis of the second electricalconnector.
 7. The power cord of claim 6, wherein each of the firstelectrical connector and second electrical connector further comprises aflange extending from the body along a plane parallel to the front faceor perpendicular to the longitudinal axis of the body.
 8. The power cordof claim 7, wherein the flange of each of the first electrical connectorand second electrical connector is offset from the front face along thelongitudinal axis of the body.
 9. The power cord of claim 7, wherein theflange of each of the first electrical connector and second electricalconnector extends circumferentially around the body
 10. The power cordof claim 6, wherein the cable is a type NM-B cable.
 11. The power cordof claim 6, wherein the first electrical connector is a femalereceptacle connector and the second electrical connector is a male prongconnector.
 12. The power cord of claim 6, wherein the first electricalconnector and the second electrical connector are integrally formed withthe cable to form a unitary power cord.
 13. The power cord of claim 6,wherein the cable extends from the body of the first electricalconnector at a 90° angle to the axis normal to the front face of thefirst electrical connector; and wherein the cable extends from the bodyof the second electrical connector at a 90° angle to the axis normal tothe front face of the second electrical connector.
 14. An electricalconnector assembly for routing power cords or audio/video cables insidea wall, the assembly comprising: a power cord terminating with a firstelectrical connector integrally provided at a first end of the powercord and terminating with a second electrical connector integrallyprovided at a second end of the power cord; wherein the power cordcomprises a type of cable that is rated for use inside walls; a firstwall grommet comprising a housing configured to be secured to the firstelectrical connector at the first end of the power cord; and a secondwall grommet comprising a housing configured to be secured to the secondelectrical connector at the second end of the power cord; wherein eachof the first wall grommet and second wall grommet is configured to beinserted through a hole in a surface of a wall and mounted in the wall,such that the power cord can be routed through an interior space of thewall.
 15. The electrical connector assembly according to claim 14,wherein the housing of the first wall grommet is configured to besecured to the first electrical connector on the first end of the powercord such that the first electrical connector is recessed from thesurface of the wall when the housing of the first wall grommet ismounted in the wall; and wherein the housing of the second wall grommetis configured to be secured to the second electrical connector on thesecond end of the power cord such that the second connector is recessedfrom the surface of the wall when the housing of the second wall grommetis mounted in the wall.
 16. The electrical connector assembly accordingto claim 15, wherein the housing of each of the first wall grommet andthe second wall grommet defines a front opening, a front interior space,a back interior space, and an interior wall separating the frontinterior space and the back interior space, the interior wall having avertical portion defining a connector opening that connects the frontinterior space and the back interior space.
 17. The electrical connectorassembly according to claim 16, wherein the back interior space definedby the housing of the first wall grommet is configured to accommodatethe first electrical connector at the first end of the power cord, suchthat the first electrical connector at the first end of the power cordis accessible from the front opening and front interior space of thehousing through the electrical-connector opening; and wherein the backinterior space defined by the housing of the second wall grommet isconfigured to accommodate the second electrical connector at the secondend of the power cord, such that the second electrical connector at thesecond end of the power cord is accessible from the front opening andfront interior space of the housing through the electrical-connectoropening.
 18. The electrical connector assembly according to claim 17,wherein the housing of each of the first wall grommet and the secondwall grommet defines a power cord opening to the back interior spaceconfigured to allow the power cord to extend out of the housingtransversely to a longitudinal axis of the housing.
 19. The electricalconnector assembly according to claim 16, wherein the housing of each ofthe first wall grommet and the second wall grommet further comprises anegress opening providing access to the front interior space of thehousing; wherein a portion of the interior wall of each of the firstwall grommet and the second wall grommet curves from a back edge of thewire egress opening toward the front interior space and the frontopening; and wherein the curved portion of the interior wall and theegress opening of each of the first wall grommet and the second wallgrommet are configured such that a cable can be routed from the frontopening of the housing of either the first wall grommet or the secondwall grommet, through the front interior space of the housing of thatwall grommet, out through the egress opening of that wall grommet, andinto the interior space of the wall when that housing is mounted in thewall.
 20. The electrical connector assembly according to claim 16,wherein each of the first and second electrical connectors comprises aflange configured to engage the interior wall of the housing around theelectrical-connector opening; wherein each of the first and secondelectrical connectors comprises a front face protruding from the flangesuch that the front face of the electrical connector extends through theelectrical-connector opening when the flange engages the interior wallof the housing around the electrical-connector opening.